Hello everyone and thanks in advance for any and all help:
Working with 1998 elpto mariner 60hp 2 stroke bigfoot serial number og696921 on a 20ft monark pontoon
the other night on the river and all was fine, stopped and floated for about a half hour or so and went to leave. Engine seemed to turn over very slow like dead battery, then wouldnt turn over at all the 2nd time. This is equipped with dual batteries and switch. I had lights and radio, but no crank. Just fyi - last summer had issues with ignition switch firing the engine and ordered switch but it never happened again, so this was one of the first things i suspected. Meanwhile i broke the key off in the cylinder while frustration kicked in from being stranded. Once back in and home here is what has been done / checked in order. Also had erratic tach readings on this boat prior to this issue.
1. Charged batteries
2. Attempted to wire in new ignition switch, this was a little confusing as my old switch had 6 poles and all filled labeled b,i,m,m,s,c - the new switch had b,i,a,s,c,m, and raised m. After doing research it appears the "i" on the new switch is not used on my application? Not sure?
3. When attempting to wire switch, im almost certain something was wired wrong initially and created no power at switch.
4. Removed hood to start looking and found severely melted / burnt,broken wires coming off the voltage regulator. Regulator itself didnt show any signs at all of overheating. Also found yellow connectors at stator were melted as well, green and green/white were ok.
5. Repaired all burnt wiring and connections and ordered a new voltage regulator ( not here yet so not installed )
6. At this time tried starting the engine and kept popping the 20a fuse at motor, found and corrected an ignition switch issue and replaced fuse. Now i get a very faint click at motor and wont turn over. When checking click, found starter solenoid clicking. Tapped on it and retried, now it fires. ( new solenoid on order as well )
7. Buttoned up dash, installed my new prop and hooked up the ears to see if it would run. It cranks wonderful but not firing now.
I have a couple different questions for sure:
My ignition switch is currently set up as follows:
A - 3 purple wires
m - 3 black wires
c - 1 yellow w/ black stripe
s - 1 yellow w/ red stripe
b - 1 red wire
m - 1 black w/ yellow stripe on the raised m connection
i - not being used
when i have my 3 purple wires connected to "a" it cranks and no tach reading, when it's hooked to "i" it too cranks and the tach registers then? Still not sure if my switch is installed 100% correctly or if i was even given the correct switch by the dealer.
Also one of the black wires from the switch goes to one of the m terminals on the kill switch and the black with yellow goes from switch to the other m connection on kill switch. There is 2 empty prongs left on the kill switch labeled a and b but they were empty with the old switch as well. So not sure if something is needed there.
I can smell fuel when trying to turn over so i am assuming i have an ignition / spark issue. I have read and researched forums for what feels like 30 hours and i am at a dead end. Again it cranks great, but doesnt even attempt to fire. Prior to this problem the boat cranked and fired perfect every time, but we always complained about performance / speed of this boat, and it seems to just eat the fuel. Not sure if either of those things are culprits or not but needed to mention. Also on a side note there has always been a light tapping sound that appears under the hood while running but has never affected performance. I was once told this was a common mariner issue and not to worry about it?
I would appreciate any help, and as i am mechanically inclined but i do not have some of the multimeters and gauges to check certain electrical issues. Also i had a fireworks accident last july and lost my right hand and wrist, so as i can still get by doing plenty of things, some things can be a bit difficult on my own. I always try to repair myself, not only to save some money where i can, but to learn, so again your help is apprecited in advance. Thank you!
Working with 1998 elpto mariner 60hp 2 stroke bigfoot serial number og696921 on a 20ft monark pontoon
the other night on the river and all was fine, stopped and floated for about a half hour or so and went to leave. Engine seemed to turn over very slow like dead battery, then wouldnt turn over at all the 2nd time. This is equipped with dual batteries and switch. I had lights and radio, but no crank. Just fyi - last summer had issues with ignition switch firing the engine and ordered switch but it never happened again, so this was one of the first things i suspected. Meanwhile i broke the key off in the cylinder while frustration kicked in from being stranded. Once back in and home here is what has been done / checked in order. Also had erratic tach readings on this boat prior to this issue.
1. Charged batteries
2. Attempted to wire in new ignition switch, this was a little confusing as my old switch had 6 poles and all filled labeled b,i,m,m,s,c - the new switch had b,i,a,s,c,m, and raised m. After doing research it appears the "i" on the new switch is not used on my application? Not sure?
3. When attempting to wire switch, im almost certain something was wired wrong initially and created no power at switch.
4. Removed hood to start looking and found severely melted / burnt,broken wires coming off the voltage regulator. Regulator itself didnt show any signs at all of overheating. Also found yellow connectors at stator were melted as well, green and green/white were ok.
5. Repaired all burnt wiring and connections and ordered a new voltage regulator ( not here yet so not installed )
6. At this time tried starting the engine and kept popping the 20a fuse at motor, found and corrected an ignition switch issue and replaced fuse. Now i get a very faint click at motor and wont turn over. When checking click, found starter solenoid clicking. Tapped on it and retried, now it fires. ( new solenoid on order as well )
7. Buttoned up dash, installed my new prop and hooked up the ears to see if it would run. It cranks wonderful but not firing now.
I have a couple different questions for sure:
My ignition switch is currently set up as follows:
A - 3 purple wires
m - 3 black wires
c - 1 yellow w/ black stripe
s - 1 yellow w/ red stripe
b - 1 red wire
m - 1 black w/ yellow stripe on the raised m connection
i - not being used
when i have my 3 purple wires connected to "a" it cranks and no tach reading, when it's hooked to "i" it too cranks and the tach registers then? Still not sure if my switch is installed 100% correctly or if i was even given the correct switch by the dealer.
Also one of the black wires from the switch goes to one of the m terminals on the kill switch and the black with yellow goes from switch to the other m connection on kill switch. There is 2 empty prongs left on the kill switch labeled a and b but they were empty with the old switch as well. So not sure if something is needed there.
I can smell fuel when trying to turn over so i am assuming i have an ignition / spark issue. I have read and researched forums for what feels like 30 hours and i am at a dead end. Again it cranks great, but doesnt even attempt to fire. Prior to this problem the boat cranked and fired perfect every time, but we always complained about performance / speed of this boat, and it seems to just eat the fuel. Not sure if either of those things are culprits or not but needed to mention. Also on a side note there has always been a light tapping sound that appears under the hood while running but has never affected performance. I was once told this was a common mariner issue and not to worry about it?
I would appreciate any help, and as i am mechanically inclined but i do not have some of the multimeters and gauges to check certain electrical issues. Also i had a fireworks accident last july and lost my right hand and wrist, so as i can still get by doing plenty of things, some things can be a bit difficult on my own. I always try to repair myself, not only to save some money where i can, but to learn, so again your help is apprecited in advance. Thank you!